Compositions and processes for separation of bitumen from oil sand ores

Abstract

Compositions and processes for separating bitumen from oil sands ore include contacting the oil sand ores with a composition including a carboxylate salt and/or acid and an aqueous liquid carrier. The carboxylate salt and/or acid is a C 1 -C 7 alkyl, and in one embodiment, is a monocarboxylate.

1 . A composition for enhancing the efficiency of bitumen recovery from oil sands ore, comprising:
 at least one C 1 -C 7  monocarboxylic acid salt and/or acid in an aqueous liquid carrier; and   oil sands ore containing bitumen, wherein the at least one C 1 -C 7  monocarboxylic acid salt and/or acid is in an amount effective to separate the oil sands into a froth phase, a middling phase, and sand and rock phase.   
     
     
         2 . The composition of  claim 1 , wherein the C 1 -C 7  monocarboxylic salt is potassium formate, sodium formate, cesium formate, ammonium formate, or a mixture thereof. 
     
     
         3 . The composition of  claim 1 , wherein the C 1 -C 7  monocarboxylic salt and/or acid is in an amount of 1 to 75 weight percent based on a total weight of the composition. 
     
     
         4 . The composition of  claim 1 , wherein the C 1 -C 7  monocarboxylic salt and/or acid is in an amount of 5 to 50 weight percent based on a total weight of the composition. 
     
     
         5 . The composition of  claim 1 , further comprising an additive in an amount of 0.01 to 10 weight percent based on a total weight of the composition, wherein the additive is a surfactant, an anti-foaming agent, a polymer, a flocculant, a mineral oil or a mixture thereof. 
     
     
         6 . A process for enhancing the efficiency of bitumen recovery from oil sands ore, comprising:
 contacting the oil sands ore containing bitumen with an aqueous solution comprising at least one C 1 -C 7  monocarboxylate salt and/or acid.   
     
     
         7 . The process of  claim 6 , wherein contacting the oil sand ore with the aqueous solution is at a temperature of 0° C. to 60° C. 
     
     
         8 . The process of  claim 6 , wherein the C 1 -C 7  monocarboxylic salt is potassium formate, sodium formate, cesium formate, ammonium formate, or a mixture 
     
     
         9 . The process of  claim 6 , further comprising adding an additive to the aqueous solution in an amount of 0.01 to 10 weight percent based on a total weight of the solution, wherein the additive is a surfactant, an anti-foaming agent, a polymer, a flocculant, a mineral oil, or a mixture thereof. 
     
     
         10 . The process of  claim 6 , wherein the oil sand is surface mined and the process further comprises recycling the aqueous solution. 
     
     
         11 . The process of  claim 6 , wherein the process is free of a heating step. 
     
     
         12 . The process of  claim 6 , wherein the oil sands ore containing the bitumen is a froth. 
     
     
         13 . The process of  claim 6 , wherein the at least one C 1 -C 7  monocarboxylic salt and/or acid is in an amount of 1 to 75 weight percent based on a total weight of the aqueous solution. 
     
     
         14 . A process for extracting bitumen from an oil sand, comprising:
 mixing oil sands ore with a first aqueous solution to form a slurry;   aerating the slurry to form a froth containing bitumen within the slurry;   separating the froth from the slurry;   adding a second aqueous solution comprising at least one C 1 -C 7  monocarboxylate salt and/or acid, wherein adding the second solution is prior to or during one or more of the preceding steps; and   isolating bitumen from the froth.   
     
     
         15 . The process of  claim 14 , wherein the C 1 -C 7  monocarboxylic salt is potassium formate, sodium formate, cesium formate, ammonium formate, or a mixture thereof. 
     
     
         16 . The process of  claim 14 , wherein the C 1 -C 7  monocarboxylic salt and/or acid is in an amount of 1 to 70 weight percent based on a total weight of the composition. 
     
     
         17 . The process of  claim 14 , wherein isolating the bitumen comprises heating the froth in an amount effective to substantially deaerate the froth; and adding naptha to the deaerated froth. 
     
     
         18 . The process of  claim 14 , wherein the first aqueous solution comprises hot water at a temperature of about 40° C. to about 90° C. 
     
     
         19 . The process of  claim 14 , wherein the first aqueous solution comprises hot water at a temperature of about 0° C. to about 60° C.